Fibrous Elements and Fibrous Structures Employing Same

ABSTRACT

Fibrous elements, such as filaments, and more particularly to fibrous elements employing a polymer and a wetting agent, methods for making such fibrous elements, fibrous structures employing such fibrous elements, methods for making such fibrous structures and packages containing such fibrous structures are provided.

FIELD OF THE INVENTION

The present invention relates to fibrous elements, such as filaments,and more particularly to fibrous elements comprising a polymer and awetting agent, methods for making such fibrous elements, fibrousstructures employing such fibrous elements, methods for making suchfibrous structures and packages comprising such fibrous structures.

BACKGROUND OF THE INVENTION

Fibrous elements (filaments and/or fibers) comprising wetting agents areknown in the art. For example, polypropylene filaments comprisingwetting agents are known in the art. Wetting agents have been used bothas surface treating agents on hydrophobic fibrous elements, such aspolypropylene filaments and/or polyester fibers, and as melt treatingagents within polymer melt compositions that are spun into filaments,such as polypropylene filaments. However, these wetting agents and/orexecutions have been less than successful, especially for smallerdiameter (diameters of less than 2 μm) filaments. As a result of theproblem of hydrophilizing inherently hydrophobic less than 2 μm diameterfilaments, fibrous structures incorporating such filaments haveexhibited hydrophobic properties depending upon the amount of suchfilaments present within the fibrous structures.

Fibrous structures comprising fibrous elements comprising wetting agentsare also known. However, due to the problems associated withconventional wetting agents and/or executions for applying wettingagents to hydrophobic fibrous elements, such as reducing the surfacetension of absorbed fluids thereby altering the ability of the fibrousstructure to hold onto the fluid, it is challenging for formulators tomake the hydrophobic fibrous structures less hydrophobic and/or evenhydrophilic.

Accordingly, there is a need for a fibrous element, such as a filament,comprising a polymer and a wetting agent that overcomes the negativesassociated with prior hydrophobic filaments and fibrous structurescomprising fibrous elements.

SUMMARY OF THE INVENTION

The present invention fulfills the needs described above by providing anovel filament comprising a polymer and a wetting agent, fibrousstructures employing same, methods for making same and packagescontaining such fibrous structures.

In one example of the present invention, a fibrous element, such as afilament, comprising a polymer and a wetting agent, wherein the wettingagent is present at a level of greater than 0% but less than 2% byweight of the fibrous element and wherein the fibrous element exhibits adiameter of less than 2 μm as measured according to the Diameter TestMethod described herein, and a contact angle of less than about 80° asmeasured according to the Contact Angle Test Method described herein, isprovided.

In another example of the present invention, a fibrous structurecomprising a fibrous element, such as a filament, of the presentinvention is provided.

In yet another example of the present invention, a method for making afibrous element such as a filament, comprising the steps of:

a. mixing a fibrous element-forming polymer and a wetting agent to makea spinning composition; and

b. spinning a fibrous element from the spinning composition such thatthe fibrous element exhibits a diameter of less than 2 μm as measuredaccording to the Diameter Test Method described herein and a contactangle of less than about 80° as measured by the Contact Angle TestMethod described herein, wherein the fibrous element comprises greaterthan 0% but less than 2% by weight of the fibrous element of the wettingagent, is provided.

In even another example of the present invention, a method for making afibrous structure comprising the step of associating a plurality offibrous elements, such as filaments, comprising a fibrouselement-forming polymer and a wetting agent present at a level ofgreater than 0% but less than 2% by weight of the fibrous elements,wherein the fibrous elements exhibit a diameter of less than 2 μm asmeasured according to the Diameter Test Method described herein and acontact angle of less than about 80° as measured according to theContact Angle Test Method described herein, such that a fibrousstructure is formed, is provided.

In even yet another example of the present invention, a method formaking a fibrous structure comprising the steps of;

a. spinning a plurality of fibrous elements, such as filaments, from aspinning composition comprising a fibrous element-forming polymer and awetting agent present at a level of greater than 0% but less than 2% byweight of the fibrous elements, wherein the fibrous elements exhibit adiameter of less than 2 μm as measured according to the Diameter TestMethod described herein and a contact angle of less than about 80° asmeasured according to the Contact Angle Test Method described herein;and

b. associating the plurality of fibrous elements such that a fibrousstructure is formed, is provided.

In still yet another example of the present invention, a method foractivating a fibrous element, such as a filament, comprising the stepsof:

a. providing a fibrous element, such as a filament, comprising a fibrouselement-forming polymer and an activatable wetting agent present at alevel of greater than 0% but less than 2% by weight of the fibrouselement, wherein the fibrous element exhibits a diameter of less than 2μm as measured according to the Diameter Test Method described hereinand a contact angle of greater than 100° as measured according to theContact Angle Test Method described herein; and

b. activating the wetting agent such that the fibrous element exhibits acontact angle of less than 80° as measured according to the ContactAngle Test Method described herein, is provided.

In even still yet another example of the present invention, a packagecomprising a fibrous structure comprising a fibrous element comprising afibrous element-forming polymer and an activatable wetting agent presentat a level of greater than 0% but less than 2% by weight of the fibrouselements wherein the fibrous element exhibits a diameter of less than 2μm as measured according to the Diameter Test Method described hereinand a contact angle of greater than 100° as measured according to theContact Angle Test Method described herein, the package furthercomprising instructions for activating the activatable wetting agent, isprovided.

Accordingly, the present invention provides fibrous elements comprisinga polymer and a wetting agent, methods for making fibrous elements,methods for making fibrous structures comprising such fibrous elementsand packages comprising such fibrous structures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of an example of a fibrousstructure according to the present invention;

FIG. 2 is a schematic, cross-sectional representation of FIG. 1 takenalong line 2-2;

FIG. 3 is a scanning electromicrophotograph of a cross-section ofanother example of fibrous structure according to the present invention;

FIG. 4 is a schematic representation of another example of a fibrousstructure according to the present invention;

FIG. 5 is a schematic, cross-sectional representation of another exampleof a fibrous structure according to the present invention;

FIG. 6 is a schematic, cross-sectional representation of another exampleof a fibrous structure according to the present invention;

FIG. 7 is a schematic representation of an example of a process formaking a fibrous structure according to the present invention;

FIG. 8 is a schematic representation of an example of a patterned beltfor use in a process according to the present invention;

FIG. 9 is a schematic representation of an example of a filament-forminghole and fluid-releasing hole from a suitable die useful in making afibrous structure according to the present invention;

FIG. 10 are cryo-scanning electromicrographs of an example of a fibrousstructure of the present invention prior to activation of the wettingagent within the polypropylene filaments; and

FIG. 11 are cryo-scanning electromicrographs of the fibrous structure ofFIG. 10 after activation of the wetting agent within the polypropylenefilaments.

DETAILED DESCRIPTION OF THE INVENTION Definitions

“Fibrous element” as used herein means an elongate particulate having alength greatly exceeding its average diameter, i.e. a length to averagediameter ratio of at least about 10. A fibrous element may be a filamentor a fiber. In one example, the fibrous element is a single fibrouselement rather than a yarn comprising a plurality of fibrous elements.

The fibrous elements of the present invention may be spun from spinningcompositions such as polymer melt compositions, via suitable spinningoperations, such as meltblowing and/or spunbonding and/or they may beobtained from natural sources such as vegetative sources, for exampletrees.

The fibrous elements of the present invention may be monocomponent ormulticomponent. For example, the fibrous elements may comprisebicomponent fibers and/or filaments. The bicomponent fibers and/orfilaments may be in any form, such as side-by-side, core and sheath,islands-in-the-sea and the like.

“Filament” as used herein means an elongate particulate as describedabove that exhibits a length of greater than or equal to 5.08 cm (2 in.)and/or greater than or equal to 7.62 cm (3 in.) and/or greater than orequal to 10.16 cm (4 in.) and/or greater than or equal to 15.24 cm (6in.).

Filaments are typically considered continuous or substantiallycontinuous in nature. Filaments are relatively longer than fibers.Non-limiting examples of filaments include meltblown and/or spunbondfilaments.

“Fiber” as used herein means an elongate particulate as described abovethat exhibits a length of less than 5.08 cm (2 in.) and/or less than3.81 cm (1.5 in.) and/or less than 2.54 cm (1 in.).

Fibers are typically considered discontinuous in nature. Non-limitingexamples of fibers include pulp fibers, such as wood pulp fibers, andsynthetic staple fibers such as polypropylene, polyethylene, polyester,copolymers thereof, rayon, glass fibers and polyvinyl alcohol fibers.

Staple fibers may be produced by spinning a filament tow and thencutting the tow into segments of less than 5.08 cm (2 in.) thusproducing fibers.

In one example of the present invention, a fiber may be a naturallyoccurring fiber, which means it is obtained from a naturally occurringsource, such as a vegetative source, for example a tree and/or plant.Such fibers are typically used in papermaking and are oftentimesreferred to as papermaking fibers. Papermaking fibers useful in thepresent invention include cellulosic fibers commonly known as wood pulpfibers. Applicable wood pulps include chemical pulps, such as Kraft,sulfite, and sulfate pulps, as well as mechanical pulps including, forexample, groundwood, thermomechanical pulp and chemically modifiedthermomechanical pulp. Chemical pulps, however, may be preferred sincethey impart a superior tactile sense of softness to tissue sheets madetherefrom. Pulps derived from both deciduous trees (hereinafter, alsoreferred to as “hardwood”) and coniferous trees (hereinafter, alsoreferred to as “softwood”) may be utilized. The hardwood and softwoodfibers can be blended, or alternatively, can be deposited in layers toprovide a stratified web. Also applicable to the present invention arefibers derived from recycled paper, which may contain any or all of theabove categories of fibers as well as other non-fibrous polymers such asfillers, softening agents, wet and dry strength agents, and adhesivesused to facilitate the original papermaking.

In addition to the various wood pulp fibers, other cellulosic fiberssuch as cotton linters, rayon, lyocell and bagasse fibers can be used inthe fibrous structures of the present invention.

“Fibrous structure” as used herein means a structure that comprises oneor more filaments and/or fibers. In one example, a fibrous structureaccording to the present invention means an orderly arrangement offilaments and/or fibers within a structure in order to perform afunction. In another example, a fibrous structure according to thepresent invention is a nonwoven.

The fibrous structures of the present invention may be homogeneous ormay be layered. If layered, the fibrous structures may comprise at leasttwo and/or at least three and/or at least four and/or at least fivelayers.

The fibrous structures of the present invention may be co-formed fibrousstructures.

In one example, the fibrous structures of the present invention aredisposable. For example, the fibrous structures of the present inventionare non-textile fibrous structures. In another example, the fibrousstructures of the present invention are flushable, such as toilettissue.

Non-limiting examples of processes for making fibrous structures includeknown wet-laid papermaking processes and air-laid papermaking processes.Such processes typically include the steps of preparing a fibrouselement composition, such as a fiber composition, in the form of asuspension in a medium, either wet, more specifically an aqueous medium,i.e., water, or dry, more specifically a gaseous medium, i.e. air. Thesuspension of fibers within an aqueous medium is oftentimes referred toas a fiber slurry. The fibrous suspension is then used to deposit aplurality of fibers onto a forming wire or belt such that an embryonicfibrous structure is formed, after which drying and/or bonding thefibers together results in the association of the fibers into a fibrousstructure. Further processing the fibrous structure may be carried outsuch that a finished fibrous structure is formed. For example, intypical papermaking processes, the finished fibrous structure is thefibrous structure that is wound on the reel at the end of papermaking.The finished fibrous structure may subsequently be converted into afinished product, e.g. a sanitary tissue product.

In one example, the fibrous structure of the present invention is a“unitary fibrous structure.”

“Unitary fibrous structure” as used herein is an arrangement comprisinga plurality of two or more and/or three or more fibrous elements thatare inter-entangled or otherwise associated with one another to form afibrous structure. A unitary fibrous structure in accordance with thepresent invention may be incorporated into a fibrous structure accordingto the present invention. A unitary fibrous structure of the presentinvention may be one or more plies within a multi-ply fibrous structure.In one example, a unitary fibrous structure of the present invention maycomprise three or more different fibrous elements. In another example, aunitary fibrous structure of the present invention may comprise twodifferent fibrous elements, for example a co-formed fibrous structure,upon which a different fibrous element is deposited to form a fibrousstructure comprising three or more different fibrous elements.

“Co-formed fibrous structure” as used herein means that the fibrousstructure comprises a mixture of at least two different materialswherein at least one of the materials comprises a filament, such as apolypropylene filament, and at least one other material, different fromthe first material, comprises a solid additive, such as a fiber and/or aparticulate. In one example, a co-formed fibrous structure comprisessolid additives, such as fibers, such as wood pulp fibers and/orabsorbent gel materials and/or filler particles and/or particulate spotbonding powders and/or clays, and filaments, such as polypropylenefilaments.

“Solid additive” as used herein means a fiber and/or a particulate.

“Particulate” as used herein means a granular substance or powder.

“Sanitary tissue product” as used herein means a soft, low density (i.e.<about 0.15 g/cm³) web useful as a wiping implement for post-urinary andpost-bowel movement cleaning (toilet tissue), for otorhinolaryngologicaldischarges (facial tissue), and multi-functional absorbent and cleaninguses (absorbent towels). Non-limiting examples of suitable sanitarytissue products of the present invention include paper towels, bathtissue, facial tissue, napkins, baby wipes, adult wipes, wet wipes,cleaning wipes, polishing wipes, cosmetic wipes, car care wipes, wipesthat comprise an active agent for performing a particular function,cleaning substrates for use with implements, such as a Swifter® cleaningwipe/pad. The sanitary tissue product may be convolutedly wound uponitself about a core or without a core to form a sanitary tissue productroll.

In one example, the sanitary tissue product of the present inventioncomprises one or more fibrous structures according to the presentinvention.

The sanitary tissue products of the present invention may exhibit abasis weight between about 10 g/m² to about 120 g/m² and/or from about15 g/m² to about 110 g/m² and/or from about 20 g/m² to about 100 g/m²and/or from about 30 to 90 g/m². In addition, the sanitary tissueproduct of the present invention may exhibit a basis weight betweenabout 40 g/m² to about 120 g/m² and/or from about 50 g/m² to about 110g/m² and/or from about 55 g/m² to about 105 g/m² and/or from about 60 to100 g/m².

The sanitary tissue products of the present invention may be in the formof sanitary tissue product rolls. Such sanitary tissue product rolls maycomprise a plurality of connected, but perforated sheets of fibrousstructure, that are separably dispensable from adjacent sheets.

The sanitary tissue products of the present invention may comprisesadditives such as softening agents, temporary wet strength agents,permanent wet strength agents, bulk softening agents, lotions,silicones, wetting agents, latexes, patterned latexes and other types ofadditives suitable for inclusion in and/or on sanitary tissue products.

“Fibrous element-forming polymer” as used herein means a polymer thatexhibits properties that make it suitable for spinning into a fibrouselement, such as a filament.

“Polysaccharide polymer” as used herein means a natural polysaccharide,a polysaccharide derivative and/or a modified polysaccharide.

“Non-polysaccharide polymer” as used herein means a polymer that is nota polysaccharide polymer as defined herein.

“Wetting agent” as used herein means a material in present in and/or ona fibrous element of the present invention, wherein the material thatlowers the surface tension of a liquid, such as water, coming intocontact with a surface of the fibrous element, allowing easier spreadingand lower interfacial tension between the liquid and the surface.

“Activatable” as used herein with reference to a wetting agent meansthat the wetting agent exhibits different properties depending on theconditions it may have been subjected to. For example, in one case, awetting agent within a fibrous element may not make the fibrous elementexhibit a contact angle of less than 80°, but after being subjected to a120° F. at 60% relative humidity for 24 hours, the wetting agent doesmake the fibrous element exhibit a contact angle of less than 80°.

“Activated wetting agent” as used herein means an activatable wettingagent that causes a fibrous element to exhibit a contact angle of lessthan 80° after the wetting agent initially failed to cause the fibrouselement to exhibit a contact angle of less than 80°.

“Non-thermoplastic” as used herein means, with respect to a material,such as a fibrous element as a whole and/or a polymer within a fibrouselement, that the fibrous element and/or polymer exhibits no meltingpoint and/or softening point, which allows it to flow under pressure, inthe absence of a plasticizer, such as water, glycerin, sorbitol, ureaand the like.

“Thermoplastic” as used herein means, with respect to a material, suchas a fibrous element as a whole and/or a polymer within a fibrouselement, that the fibrous element and/or polymer exhibits a meltingpoint and/or softening point at a certain temperature, which allows itto flow under pressure, even in the absence of a plasticizer

“Non-cellulose-containing” as used herein means that less than 5% and/orless than 3% and/or less than 1% and/or less than 0.1% and/or 0% byweight of cellulose polymer, cellulose derivative polymer and/orcellulose copolymer is present in fibrous element. In one example,“non-cellulose-containing” means that less than 5% and/or less than 3%and/or less than 1% and/or less than 0.1% and/or 0% by weight ofcellulose polymer is present in a fibrous element of the presentinvention.

“Random mixture of polymers” as used herein means that two or moredifferent polymers are randomly combined to form a fibrous element.Accordingly, two or more different polymers that are orderly combined toform a fibrous element, such as a core and sheath bicomponent fibrouselement, is not a random mixture of different polymers for purposes ofthe present invention.

“Associate,” “Associated,” “Association,” and/or “Associating” as usedherein with respect to fibrous elements means combining, either indirect contact or in indirect contact, fibrous elements such that afibrous structure is formed. In one example, the associated fibrouselements may be bonded together for example by adhesives and/or thermalbonds. In another example, the fibrous elements may be associated withone another by being deposited onto the same fibrous structure makingbelt and/or patterned belt.

“Weight average molecular weight” as used herein means the weightaverage molecular weight as determined using gel permeationchromatography according to the protocol found in Colloids and SurfacesA. Physico Chemical & Engineering Aspects, Vol. 162, 2000, pg. 107-121.

“Diameter” as used herein, with respect to a fibrous element, ismeasured according to the Diameter Test Method described herein. In oneexample, a fibrous element, such as a filament, of the present inventionexhibits a diameter of less than 2 μm and/or less than 1.5 μm and/orless than 1 μm and/or greater than 0.01 μm and/or greater than 0.1 μmand/or greater than 0.5 μm as measured according to the Diameter TestMethod described herein.

“Basis Weight” as used herein is the weight per unit area of a samplereported in lbs/3000 ft² or g/m².

“Ply” or “Plies” as used herein means an individual fibrous structureoptionally to be disposed in a substantially contiguous, face-to-facerelationship with other plies, forming a multiple ply fibrous structure.It is also contemplated that a single fibrous structure can effectivelyform two “plies” or multiple “plies”, for example, by being folded onitself.

As used herein, the articles “a” and “an” when used herein, for example,“an anionic surfactant” or “a fiber” is understood to mean one or moreof the material that is claimed or described.

All percentages and ratios are calculated by weight unless otherwiseindicated. All percentages and ratios are calculated based on the totalcomposition unless otherwise indicated.

Unless otherwise noted, all component or composition levels are inreference to the active level of that component or composition, and areexclusive of impurities, for example, residual solvents or by-products,which may be present in commercially available sources.

Fibrous Elements

The fibrous elements of the present invention may be synthetic. In otherwords, the fibrous elements of the present invention may be “human-made”rather than naturally occurring (found in nature). The fibrous elementsof the present invention comprise a polymer and a wetting agent. Thepolymer may be a fibrous element-forming polymer. The fibrous elementsof the present invention may comprise greater than 30% and/or greaterthan 40% and/or greater than 50% and/or greater than 60% and/or greaterthan 70% to about 100% and/or to about 95% and/or to about 90% by weightof the filament of one or more polymers.

The fibrous elements of the present invention may comprise greater than0% and/or greater than 0.5% and/or greater than 0.75% to less than 2%and/or less than 1.75% and/or less than 1.5% by weight of the fibrouselements of one or more wetting agents.

The fibrous elements of the present invention may associate to form afibrous structure of the present invention.

In one example, the fibrous element comprises a filament.

The fibrous elements may be a single component (i.e., single syntheticmaterial or mixture makes up entire fibrous element), bi-component(i.e., the fibrous element is divided into regions, the regionsincluding two or more different polymers or mixtures thereof and mayinclude co-extruded fibrous elements) and mixtures thereof. It is alsopossible to use bicomponent fibrous elements, or simply bicomponent orsheath polymers. These bicomponent fibrous elements can be used as acomponent fibrous element of the structure, and/or they may be presentto act as a binder for other fibrous elements present in the fibrousstructure. Any or all of the fibrous elements may be treated before,during, or after the process of the present invention to change anydesired properties of the fibrous elements. For example, in certainembodiments, it may be desirable to treat (for example, make the fibrouselements less hydrophobic or more hydrophilic) the fibrous elementsbefore, during or after making the fibrous elements and/or before,during or after making a fibrous structure.

Polymer

Non-limiting examples of suitable polymers for use in the fibrouselements of the present invention include polyolefins. In anotherexample, the polymer of the present invention may be selected from thegroup consisting of: polyesters, polypropylenes, polyethylenes,polyethers, polyamides, polyhydroxyalkanoates, polysaccharides,polyvinyl alcohol, copolymers thereof, and mixtures thereof. Anon-limiting example of a suitable polyester comprises polyethyleneterephthalate.

In one example, the polymer is a non-polysaccharide polymer. Thenon-polysaccharide polymer of the present invention, which, for purposesof the present invention, does not include cellulose, cellulosederivatives, hemicellulose, hemicellulose derivatives, starch and starchderivatives. In addition to the non-polysaccharide polymers, thefilaments may comprise polysaccharide polymers. Non-limiting examples ofsuitable polysaccharide polymers include starch, starch derivatives,cellulose, cellulose derivatives, hemicellulose, hemicellulosederivatives and mixtures thereof. The polysaccharide polymers mayexhibit a weight average molecular weight of from about 10,000 g/mol toabout 40,000,000 g/mol and/or greater than about 100,000 g/mol and/orgreater than about 1,000,000 g/mol and/or greater than about 3,000,000g/mol and/or greater than about 3,000,000 g/mol to about 40,000,000g/mol.

The polymer of the present invention may be a thermoplastic polymer. Thethermoplastic polymer of the present invention may be a biodegradablepolymer, such as polylactic acid, polyhydroxyalkanoate,polycaprolactone, polyesteramides and certain polyesters.

Any suitable weight average molecular weight for the polymer of thepresent invention may be used. For example, the weight average molecularweight for a non-polysaccharide polymer in accordance with the presentinvention is greater than 10,000 g/mol and/or greater than 40,000 g/moland/or greater than 50,000 g/mol and/or less than 500,000 g/mol and/orless than 400,000 g/mol and/or less than 200,000 g/mol. In one example,the polypropylene present in the polypropylene fibrous elements exhibitsa weight average molecular weight of at least 78,000 g/mol and/or atleast 80,000 g/mol and/or at least 82,000 g/mol and/or at least 85,000g/mol and/or to about 500,000 g/mol and/or to about 400,000 g/mol and/orto about 200,000 g/mol and/or to about 100,000 g/mol.

The polypropylene present in the polypropylene fibrous elements mayexhibit a polydispersity of less than 3.2 and/or less than 3.1 and/orless than 3.0, is provided.

Fibrous elements, such as filaments, comprising the polymers of thepresent invention, in the absence of a wetting agent, may exhibit aconditioned contact angle of greater than 100° and/or a contact anglegreater than 110° as measured according to the Contact Angle Test Methoddescribed herein.

Wetting Agent

The wetting agent of the present invention may comprise any suitablewetting agent that can be added to a composition, such as a spinningcomposition, comprising a polymer, such as a fibrous element-formingpolymer. In one example, the wetting agent is present in a spinningcomposition comprising the polymer prior to spinning a filament from thespinning composition. In one example, the wetting agent may be in an“unactivated state,” meaning that its presence in and/or on the filamentis not resulting in the filament exhibiting a contact angle of less than80° as measured according to the Contact Angle Test Method. In anotherexample, the wetting agent may be in an “activated state,” meaning thatits presence in and/or on the filament is resulting in the filamentexhibiting a contact angle of less than 80° as measured according to theContact Angle Test Method.

Non-limiting examples of suitable wetting agents include surfactants,such as silicone surfactants, polyethylene glycols, glycols and mixturesthereof. One commercially available wetting agent suitable for thepresent invention is sold under the trade name Polvyvel S1-1416 byPolyvel Inc. of Hammonton, N.J., which is sold as 20% active wettingagent. Any suitable wetting agent may be used so long as its presence inthe fibrous elements produces the fibrous elements according to thepresent invention.

In one example, the fibrous element of the present invention is void ofsurface treating wetting agents that are applied (in an amount to causethe fibrous element to exhibit a contact angle of less than 80°) to anexternal surface of the fibrous element.

Fibrous Structures

The fibrous structures of the present invention may comprises aplurality of fibrous elements. In one example, a fibrous structure ofthe present invention comprises a plurality of filaments, such aspolypropylene filaments. In another example, a fibrous structure of thepresent invention may comprise a plurality of filaments, such aspolypropylene filaments, and a plurality of solid additives, such aswood pulp fibers. The fibrous structures of the present invention havebeen found to exhibit consumer-recognizable beneficial absorbentcapacity.

FIGS. 1 and 2 show schematic representations of an example of a fibrousstructure in accordance with the present invention. As shown in FIGS. 1and 2 , the fibrous structure 10 may be a co-formed fibrous structure.The fibrous structure 10 comprises a plurality of filaments 12, such aspolypropylene filaments, and a plurality of solid additives, such aswood pulp fibers 14. The filaments 12 may be randomly arranged as aresult of the process by which they are spun and/or formed into thefibrous structure 10. The wood pulp fibers 14, may be randomly dispersedthroughout the fibrous structure 10 in the x-y plane. The wood pulpfibers 14 may be non-randomly dispersed throughout the fibrous structurein the z-direction. In one example (not shown), the wood pulp fibers 14are present at a higher concentration on one or more of the exterior,x-y plane surfaces than within the fibrous structure along thez-direction.

FIG. 3 shows a cross-sectional, SEM microphotograph of another exampleof a fibrous structure 10 a in accordance with the present inventionshows a fibrous structure 10 a comprising a non-random, repeatingpattern of microregions 15 a and 15 b. The microregion 15 a (typicallyreferred to as a “pillow”) exhibits a different value of a commonintensive property than microregion 15 b (typically referred to as a“knuckle”). In one example, the microregion 15 b is a continuous orsemi-continuous nextwork and the microregion 15 a are discrete regionswithin the continuous or semi-continuous network. The common intensiveproperty may be caliper. In another example, the common intensiveproperty may be density.

As shown in FIG. 4 , another example of a fibrous structure inaccordance with the present invention is a layered fibrous structure 10b. The layered fibrous structure 10 b comprises a first layer 16comprising a plurality of filaments 12, such as polypropylene filaments,and a plurality of solid additives, in this example, wood pulp fibers14. The layered fibrous structure 10 b further comprises a second layer18 comprising a plurality of filaments 20, such as polypropylenefilaments. In one example, the first and second layers 16, 18,respectively, are sharply defined zones of concentration of thefilaments and/or solid additives. The plurality of filaments 20 may bedeposited directly onto a surface of the first layer 16 to form alayered fibrous structure that comprises the first and second layers 16,18, respectively.

Further, the layered fibrous structure 10 b may comprise a third layer22, as shown in FIG. 4 . The third layer 22 may comprise a plurality offilaments 24, which may be the same or different from the filaments 20and/or 16 in the second 18 and/or first 16 layers. As a result of theaddition of the third layer 22, the first layer 16 is positioned, forexample sandwiched, between the second layer 18 and the third layer 22.The plurality of filaments 24 may be deposited directly onto a surfaceof the first layer 16, opposite from the second layer, to form thelayered fibrous structure 10 b that comprises the first, second andthird layers 16, 18, 22, respectively.

As shown in FIG. 5 , a cross-sectional schematic representation ofanother example of a fibrous structure in accordance with the presentinvention comprising a layered fibrous structure 10 c is provided. Thelayered fibrous structure 10 c comprises a first layer 26, a secondlayer 28 and optionally a third layer 30. The first layer 26 comprises aplurality of filaments 12, such as polypropylene filaments, and aplurality of solid additives, such as wood pulp fibers 14. The secondlayer 28 may comprise any suitable filaments, solid additives and/orpolymeric films. In one example, the second layer 28 comprises aplurality of filaments 34. In one example, the filaments 34 comprise apolymer selected from the group consisting of: polysaccharides,polysaccharide derivatives, polyvinylalcohol, polyvinylalcoholderivatives and mixtures thereof.

In another example of a fibrous structure in accordance with the presentinvention, instead of being layers of fibrous structure 10 c, thematerial forming layers 26, 28 and 30, may be in the form of plieswherein two or more of the plies may be combined to form a fibrousstructure. The plies may be bonded together, such as by thermal bondingand/or adhesive bonding, to form a multi-ply fibrous structure.

Another example of a fibrous structure of the present invention inaccordance with the present invention is shown in FIG. 6 . The fibrousstructure 10 d may comprise two or more plies, wherein one ply 36comprises any suitable fibrous structure in accordance with the presentinvention, for example fibrous structure 10 as shown and described inFIGS. 1 and 2 and another ply 38 comprising any suitable fibrousstructure, for example a fibrous structure comprising filaments 12, suchas polypropylene filaments. The fibrous structure of ply 38 may be inthe form of a net and/or mesh and/or other structure that comprisespores that expose one or more portions of the fibrous structure 10 d toan external environment and/or at least to liquids that may come intocontact, at least initially, with the fibrous structure of ply 38. Inaddition to ply 38, the fibrous structure 10 d may further comprise ply40. Ply 40 may comprise a fibrous structure comprising filaments 12,such as polypropylene filaments, and may be the same or different fromthe fibrous structure of ply 38.

Two or more of the plies 36, 38 and 40 may be bonded together, such asby thermal bonding and/or adhesive bonding, to form a multi-ply fibrousstructure. After a bonding operation, especially a thermal bondingoperation, it may be difficult to distinguish the plies of the fibrousstructure 10 d and the fibrous structure 10 d may visually and/orphysically be a similar to a layered fibrous structure in that one wouldhave difficulty separating the once individual plies from each other. Inone example, ply 36 may comprise a fibrous structure that exhibits abasis weight of at least about 15 g/m² and/or at least about 20 g/m²and/or at least about 25 g/m² and/or at least about 30 g/m² up to about120 g/m² and/or 100 g/m² and/or 80 g/m² and/or 60 g/m² and the plies 38and 42, when present, independently and individually, may comprisefibrous structures that exhibit basis weights of less than about 10 g/m²and/or less than about 7 g/m² and/or less than about 5 g/m² and/or lessthan about 3 g/m² and/or less than about 2 g/m² and/or to about 0 g/m²and/or 0.5 g/m².

Plies 38 and 40, when present, may help retain the solid additives, inthis case the wood pulp fibers 14, on and/or within the fibrousstructure of ply 36 thus reducing lint and/or dust (as compared to asingle-ply fibrous structure comprising the fibrous structure of ply 36without the plies 38 and 40) resulting from the wood pulp fibers 14becoming free from the fibrous structure of ply 36.

The fibrous structures of the present invention may comprise anysuitable amount of filaments and any suitable amount of solid additives.For example, the fibrous structures may comprise from about 10% to about70% and/or from about 20% to about 60% and/or from about 30% to about50% by dry weight of the fibrous structure of filaments and from about90% to about 30% and/or from about 80% to about 40% and/or from about70% to about 50% by dry weight of the fibrous structure of solidadditives, such as wood pulp fibers.

In one example, the fibrous structures of the present invention compriseless than 30% and/or less than 25% and/or less than 20% and/or less than15% and/or to about 10% by weight of the fibrous structure of filaments.

In one example, the fibrous structures of the present invention maycomprise at least 70% and/or at least 75% and/or at least 80% and/or atleast 85% and/or to about 90% by weight of the fibrous structures ofsolid additives, such as fibers.

The filaments and solid additives of the present invention may bepresent in fibrous structures according to the present invention atweight ratios of filaments to solid additives of from at least about 1:1and/or at least about 1:1.5 and/or at least about 1:2 and/or at leastabout 1:2.5 and/or at least about 1:3 and/or at least about 1:4 and/orat least about 1:5 and/or at least about 1:7 and/or at least about 1:10.

The fibrous structures of the present invention and/or any sanitarytissue products comprising such fibrous structures may be subjected toany post-processing operations such as embossing operations, printingoperations, tuft-generating operations, thermal bonding operations,ultrasonic bonding operations, perforating operations, surface treatmentoperations such as application of lotions, silicones and/or othermaterials and mixtures thereof.

Non-limiting examples of suitable polypropylenes for making thefilaments of the present invention are commercially available fromLyondell-Basell and Exxon-Mobil.

Any hydrophobic or non-hydrophilic materials within the fibrousstructure, such as polypropylene filaments, may be surface treatedand/or melt treated with a hydrophilic modifier. Non-limiting examplesof surface treating hydrophilic modifiers include surfactants, such asTriton X-100. Non-limiting examples of melt treating hydrophilicmodifiers that are added to the melt, such as the polypropylene melt,prior to spinning filaments, include hydrophilic modifying meltadditives such as VW351 and/or S-1416 commercially available fromPolyvel, Inc. and Irgasurf commercially available from Ciba. Thehydrophilic modifier may be associated with the hydrophobic ornon-hydrophilic material at any suitable level known in the art. In oneexample, the hydrophilic modifier is associated with the hydrophobic ornon-hydrophilic material at a level of less than about 20% and/or lessthan about 15% and/or less than about 10% and/or less than about 5%and/or less than about 3% to about 0% by dry weight of the hydrophobicor non-hydrophilic material.

The filaments and/or fibrous structures containing the filaments of thepresent invention exhibit a contact angle of less than 80° and/or lessthan 75° and/or less than 65° and/or less than 50° as measured by theContact Angle Test Method described herein.

The fibrous structures of the present invention may include optionaladditives, each, when present, at individual levels of from about 0%and/or from about 0.01% and/or from about 0.1% and/or from about 1%and/or from about 2% to about 95% and/or to about 80% and/or to about50% and/or to about 30% and/or to about 20% by dry weight of the fibrousstructure. Non-limiting examples of optional additives include permanentwet strength agents, temporary wet strength agents, dry strength agentssuch as carboxymethylcellulose and/or starch, softening agents, lintreducing agents, opacity increasing agents, wetting agents, odorabsorbing agents, perfumes, temperature indicating agents, color agents,dyes, osmotic materials, microbial growth detection agents,antibacterial agents and mixtures thereof.

The fibrous structure of the present invention may itself be a sanitarytissue product. It may be convolutedly wound about a core to form aroll. It may be combined with one or more other fibrous structures as aply to form a multi-ply sanitary tissue product. In one example, aco-formed fibrous structure of the present invention may be convolutedlywound about a core to form a roll of co-formed sanitary tissue product.The rolls of sanitary tissue products may also be coreless.

Method for Making a Fibrous Element

The fibrous elements of the present invention, for example the filamentsof the present invention, may be made by any suitable method forspinning fibrous elements, such as filaments. For example, filaments ofthe present invention may be created by meltblowing a spinningcomposition comprising a polymer, such as a filament-forming polymer,and a wetting agent from a meltblow die. Non-limiting examples ofcommercially available meltblow dies are Biax-Fiberfilm's (Greenville,Wis.) meltblow dies and knife-edge dies.

Method for Making a Fibrous Structure

A non-limiting example of a method for making a fibrous structureaccording to the present invention is represented in FIG. 7 . The methodshown in FIG. 7 comprises the step of mixing a plurality of solidadditives 14 with a plurality of filaments 12 made from a polymer meltcomposition comprising polypropylene and a wetting agent. In oneexample, the solid additives 14 are wood pulp fibers, such as SSK fibersand/or Eucalytpus fibers, and the filaments 12 are polypropylenefilaments. The solid additives 14 may be combined with the filaments 12,such as by being delivered to a stream of filaments 12 from a hammermill42 via a solid additive spreader 44 to form a mixture of filaments 12and solid additives 14. The filaments 12 may be created by meltblowingfrom a meltblow die 46. The mixture of solid additives 14 and filaments12 are collected on a collection device, such as a belt 48 to form afibrous structure 50. The collection device may be a patterned and/ormolded belt that results in the fibrous structure exhibiting a surfacepattern, such as a non-random, repeating pattern of microregions. Thepatterned belt may have a three-dimensional pattern on it that getsimparted to the fibrous structure 50 during the process. For example,the patterned belt 52, as shown in FIG. 8 , may comprise a reinforcingstructure, such as a fabric 54, upon which a polymer resin 56 is appliedin a pattern. The pattern may comprise a continuous or semi-continuousnetwork 58 of the polymer resin 56 within which one or more discreteconduits 60 are arranged.

In one example of the present invention, the fibrous structures are madeusing a die comprising at least one filament-forming hole, and/or 2 ormore and/or 3 or more rows of filament-forming holes from whichfilaments are spun. At least one row of holes contains 2 or more and/or3 or more and/or 10 or more filament-forming holes. In addition to thefilament-forming holes, the die comprises fluid-releasing holes, such asgas-releasing holes, in one example air-releasing holes, that provideattenuation to the filaments formed from the filament-forming holes. Oneor more fluid-releasing holes may be associated with a filament-forminghole such that the fluid exiting the fluid-releasing hole is parallel orsubstantially parallel (rather than angled like a knife-edge die) to anexterior surface of a filament exiting the filament-forming hole. In oneexample, the fluid exiting the fluid-releasing hole contacts theexterior surface of a filament formed from a filament-forming hole at anangle of less than 30° and/or less than 20° and/or less than 10° and/orless than 5° and/or about 0°. One or more fluid releasing holes may bearranged around a filament-forming hole. In one example, one or morefluid-releasing holes are associated with a single filament-forming holesuch that the fluid exiting the one or more fluid releasing holescontacts the exterior surface of a single filament formed from thesingle filament-forming hole. In one example, the fluid-releasing holepermits a fluid, such as a gas, for example air, to contact the exteriorsurface of a filament formed from a filament-forming hole rather thancontacting an inner surface of a filament, such as what happens when ahollow filament is formed.

In one example, the die comprises a filament-forming hole positionedwithin a fluid-releasing hole. The fluid-releasing hole 62 may beconcentrically or substantially concentrically positioned around afilament-forming hole 64 such as is shown in FIG. 9 .

After the fibrous structure 50 has been formed on the collection device,the fibrous structure 50 may be calendered, for example, while thefibrous structure is still on the collection device. In addition, thefibrous structure 50 may be subjected to post-processing operations suchas embossing, thermal bonding, tuft-generating operations,moisture-imparting operations, and surface treating operations to form afinished fibrous structure. One example of a surface treating operationthat the fibrous structure may be subjected to is the surfaceapplication of an elastomeric binder, such as ethylene vinyl acetate(EVA), latexes, and other elastomeric binders. Such an elastomericbinder may aid in reducing the lint created from the fibrous structureduring use by consumers. The elastomeric binder may be applied to one ormore surfaces of the fibrous structure in a pattern, especially anon-random, repeating pattern of microregions, or in a manner thatcovers or substantially covers the entire surface(s) of the fibrousstructure.

In one example, the fibrous structure 50 and/or the finished fibrousstructure may be combined with one or more other fibrous structures. Forexample, another fibrous structure, such as a filament-containingfibrous structure, such as a polypropylene filament fibrous structuremay be associated with a surface of the fibrous structure 50 and/or thefinished fibrous structure. The polypropylene filament fibrous structuremay be formed by meltblowing polypropylene filaments (filaments thatcomprise a second polymer that may be the same or different from thepolymer of the filaments in the fibrous structure 50) onto a surface ofthe fibrous structure 50 and/or finished fibrous structure. In anotherexample, the polypropylene filament fibrous structure may be formed bymeltblowing filaments comprising a second polymer that may be the sameor different from the polymer of the filaments in the fibrous structure50 onto a collection device to form the polypropylene filament fibrousstructure. The polypropylene filament fibrous structure may then becombined with the fibrous structure 50 or the finished fibrous structureto make a two-ply fibrous structure—three-ply if the fibrous structure50 or the finished fibrous structure is positioned between two plies ofthe polypropylene filament fibrous structure like that shown in FIG. 6for example. The polypropylene filament fibrous structure may bethermally bonded to the fibrous structure 50 or the finished fibrousstructure via a thermal bonding operation.

In yet another example, the fibrous structure 50 and/or finished fibrousstructure may be combined with a filament-containing fibrous structuresuch that the filament-containing fibrous structure, such as apolysaccharide filament fibrous structure, such as a starch filamentfibrous structure, is positioned between two fibrous structures 50 ortwo finished fibrous structures like that shown in FIG. 6 for example.

In still another example, two plies of fibrous structure 50 comprising anon-random, repeating pattern of microregions may be associated with oneanother such that protruding microregions, such as pillows, face inwardinto the two-ply fibrous structure formed.

The process for making fibrous structure 50 may be close coupled (wherethe fibrous structure is convolutedly wound into a roll prior toproceeding to a converting operation) or directly coupled (where thefibrous structure is not convolutedly wound into a roll prior toproceeding to a converting operation) with a converting operation toemboss, print, deform, surface treat, or other post-forming operationknown to those in the art. For purposes of the present invention, directcoupling means that the fibrous structure 50 can proceed directly into aconverting operation rather than, for example, being convolutedly woundinto a roll and then unwound to proceed through a converting operation.

The process of the present invention may include preparing individualrolls of fibrous structure and/or sanitary tissue product comprisingsuch fibrous structure(s) that are suitable for consumer use.

Non-Limiting Example of Method for Making a Fibrous Structure

A 20%:27.5%47.5%:5% blend of Lyondell-Basell PH835 polypropylene:Lyondell-Basell Metocene MF650W polypropylene: Exxon-Mobil PP3546polypropylene: Polyvel S-1416 wetting agent (20% of the 5% is wettingagent) is dry blended, to form a melt blend. The melt blend is heated to475° F. through a melt extruder. A 15.5 inch wide Biax 12 rowspinnerette with 192 nozzles per cross-direction inch, commerciallyavailable from Biax Fiberfilm Corporation, is utilized. 40 nozzles percross-direction inch of the 192 nozzles have a 0.018 inch insidediameter while the remaining nozzles are solid, i.e. there is no openingin the nozzle. Approximately 0.19 grams per hole per minute (ghm) of themelt blend is extruded from the open nozzles to form meltblown filamentsfrom the melt blend. Approximately 375 SCFM of compressed air is heatedsuch that the air exhibits a temperature of 395° F. at the spinnerette.Approximately 475 g/minute of Golden Isle (from Georgia Pacific) 4825semi-treated SSK pulp is defibrillated through a hammermill to form SSKwood pulp fibers (solid additive). Air at 85-90° F. and 85% relativehumidity (RH) is drawn into the hammermill. Approximately 1200 SCFM ofair carries the pulp fibers to a solid additive spreader. The solidadditive spreader turns the pulp fibers and distributes the pulp fibersin the cross-direction such that the pulp fibers are injected into themeltblown filaments in a perpendicular fashion through a 4 inch×15 inchcross-direction (CD) slot. A forming box surrounds the area where themeltblown filaments and pulp fibers are commingled. This forming box isdesigned to reduce the amount of air allowed to enter or escape fromthis commingling area; however, there is an additional 4 inch×15 inchspreader opposite the solid additive spreader designed to add coolingair. Approximately 1000 SCFM of air at approximately 80° F. is addedthrough this additional spreader. A forming vacuum pulls air through acollection device, such as a patterned belt, thus collecting thecommingled meltblown filaments and pulp fibers to form a fibrousstructure comprising a pattern of non-random, repeating microregions.The fibrous structure formed by this process comprises about 75% by dryfibrous structure weight of pulp and about 25% by dry fibrous structureweight of meltblown filaments.

FIG. 10 shows cryo-scanning electromicrographs of the fibrous structuremade as described above without the solid additives and prior toactivation of the wetting agent within the polypropylene filaments. Thefibrous structure of FIG. 10 exhibited a contact angle of about 135° asmeasured by the Contact Angle Test Method described herein. FIG. 11shows cryo-scanning electromicrographs of the fibrous structure of FIG.10 after activation of the wetting agent within the polypropylenefilaments by subjecting the fibrous structure to 120° F. at a relativehumidity of 60% for 24 hours. The fibrous structure of FIG. 11 exhibiteda contact angle of about 43° as measured according to the Contact AngleTest Method described herein.

Optionally, a meltblown layer of the meltblown filaments can be added toone or both sides of the above formed fibrous structure. This additionof the meltblown layer can help reduce the lint created from the fibrousstructure during use by consumers and is preferably performed prior toany thermal bonding operation of the fibrous structure. The meltblownfilaments for the exterior layers can be the same or different than themeltblown filaments used on the opposite layer or in the centerlayer(s).

The fibrous structure may be convolutedly wound to form a roll offibrous structure.

Test Methods

Unless otherwise indicated, all tests described herein including thosedescribed under the Definitions section and the following test methodsare conducted on samples that have been conditioned in a conditionedroom at a temperature of 73° F.±4° F. (about 23° C.±2.2° C.) and arelative humidity of 50%±10% for 2 hours prior to the test. Samplesconditioned as described herein are considered dry samples (such as “dryfibrous structures”) for purposes of this invention. Further, all testsare conducted in such conditioned room.

Elongation, Tensile Strength, TEA and Modulus Test Methods

Cut at least eight 1 inch wide strips of the fibrous structure and/orsanitary tissue product to be tested in the machine direction. Cut atleast eight 1 inch wide strips in the cross direction. If the machinedirection and cross direction are not readily ascertainable, then thecross direction will be the strips that result in the lower peak loadtensile. For the wet measurements, each sample is wetted by submergingthe sample in a distilled water bath for 30 seconds. The wet property ofthe wet sample is measured within 30 seconds of removing the sample fromthe bath.

For the actual measurements of the properties, use a Thwing-AlbertIntelect II Standard Tensile Tester (Thwing-Albert Instrument Co. ofPhiladelphia, Pa.). Insert the flat face clamps into the unit andcalibrate the tester according to the instructions given in theoperation manual of the Thwing-Albert Intelect II. Set the instrumentcrosshead speed to 4.00 in/min and the 1st and 2nd gauge lengths to 4.00inches. The break sensitivity is set to 20.0 grams and the sample widthis set to 1.00 inch. The energy units are set to TEA and the tangentmodulus (Modulus) trap setting is set to 38.1 g.

After inserting the fibrous structure sample strip into the two clamps,the instrument tension can be monitored. If it shows a value of 5 gramsor more, the fibrous structure sample strip is too taut. Conversely, ifa period of 2-3 seconds passes after starting the test before any valueis recorded, the fibrous structure sample strip is too slack.

Start the tensile tester as described in the tensile tester instrumentmanual. When the test is complete, read and record the following withunits of measure:

Peak Load Tensile (Tensile Strength) (g/in)

Peak Elongation (Elongation) (%) (The average of MD Elongation and CDElongation is reported as the Average Elongation)

Peak CD TEA (Wet CD TEA) (in-g/in²)

Tangent Modulus (Dry MD Modulus and Dry CD Modulus) (at 15 g/cm)

Test each of the samples in the same manner, recording the abovemeasured values from each test. Average the values for each propertyobtained from the samples tested to obtain the reported value for thatproperty.

Basis Weight Test Method

Basis weight of a fibrous structure sample is measured by selectingtwelve (12) individual fibrous structure samples and making two stacksof six individual samples each. If the individual samples are connectedto one another vie perforation lines, the perforation lines must bealigned on the same side when stacking the individual samples. Aprecision cutter is used to cut each stack into exactly 3.5 in.×3.5 in.squares. The two stacks of cut squares are combined to make a basisweight pad of twelve squares thick. The basis weight pad is then weighedon a top loading balance with a minimum resolution of 0.01 g. The toploading balance must be protected from air drafts and other disturbancesusing a draft shield. Weights are recorded when the readings on the toploading balance become constant. The Basis Weight is calculated asfollows:

${\begin{matrix}{{Basis}{Weight}} \\( {{lbs}/3000{ft}^{2}} )\end{matrix} = \frac{{Weight}{of}{basis}{weight}{pad}(g) \times 3000{ft}^{2}}{\begin{matrix}{453.6g/{lbs} \times 12{sample} \times} \\\lbrack {12.25{in}^{2}{( {{Area}{of}{basis}{weight}{pad}} )/144}{in}^{2}} \rbrack\end{matrix}}}{\begin{matrix}{{Basis}{Weight}} \\( {g/m^{2}} )\end{matrix} = \frac{{Weight}{of}{basis}{weight}{pad}(g) \times 10,000{cm}^{2}/m^{2}}{79.0321{cm}^{2}( {( {{Area}{of}{basis}{weight}{pad}} ) \times 12{samples}} }}$

The filament basis weight of a fibrous structure is determined using theBasis Weight Test Method after separating all non-polypropylenematerials from a fibrous structure (examples of methods for completingthe separation are described below in the Weight Average MolecularWeight/Polydispersity Test Method).

Weight Average Molecular Weight/Polydispersity Test Method

The weight average molecular weight of the polypropylene present in thepolypropylene fibrous elements, such as polypropylene filaments, afibrous structure is determined by high temperature gel permeationchromatography (GPC). Any non-propylene material present in the fibrousstructure must be separated from the polypropylene filaments. Differentapproaches may be used to achieve this separation. For example, thepolypropylene filaments may be first removed by physically pulling thepolypropylene filaments from the fibrous structure. In another example,the polypropylene filaments may be separated from the non-polypropylenematerial by dissolving the non-polypropylene material in an appropriatedissolution agent, such as sulfuric acid or Cadoxen.

In yet another approach, the step of separating the polypropylenefilaments from non-polypropylene material may be combined with thedissolution of the polypropylene such that a portion of the fibrousstructure with about 30 mg of polypropylene is placed in about 10-15 mlof 1,2,4-tricholorbenzene (TCB). This is heated to about 150° C. forabout 3 hours with gentle shaking during the last 20 minutes of heating.This process dissolves the polypropylene. The hot TCBsolution/suspension is then filtered through a heated 2-10 μm stainlesssteel frit (filter) to remove the undissolved material(non-polypropylene material).

The weight average molecular weight distribution and polydispersity (Mwand PD (PD=Mw/Mn)) are measured using GPC with refractive index (RI)detection based on polystyrene (PS) narrow standard retention times withk and a correction values applied (PS narrow standards: k=4.14, a=0.61;Polypropylene: k=1.56, a=0.76). The GPC uses 10 mm Mixed B (3) columnswith TCB containing 0.5% BHT as mobile phase at 150° C. with a 1ml/minute flow rate. Sample injection volume is 200

Diameter Test Method

The diameter of a polypropylene fibrous element, especially apolypropylene microfiber fibrous element, in a fibrous structure isdetermined by taking scanning electromicrographs of the fibrousstructure and determining the diameter of the polypropylene fibrouselement from its image.

Alternatively, the diameter of a polypropylene fibrous element,especially a polypropylene microfiber fibrous element, is determined byremoving, if necessary, the polypropylene fibrous element to be testedfrom a fibrous structure containing such polypropylene fibrous element.The polypropylene fibrous element is placed under an optical microscope.The diameter of the polypropylene fibrous element is measured using acalibrated reticle and an objective of 100 power. Read the diameter ofthe polypropylene fibrous element in at least 3 positions (in the centerof the visible polypropylene fibrous element and at 2 or more positionsalong the length of the polypropylene fibrous element near oppositeboundaries of the viewing area). The average of the diametermeasurements at the 3 or more positions is averaged and reported as thediameter of the polypropylene fibrous element.

Contact Angle Test Method

In order to prepare the samples (fibrous structures and/or fibrouselements) for contact angle measurement, the samples must beconditioned. The samples must be washed 3 times with distilled water.The samples are air dried at 73° F. Next, the samples are subjected to120° F. at a relative humidity of 60% for 24 hours. The samples are thenallowed to return to 73° F. The samples are tested in the conditionedroom described above It is important to not permit the conditionedsamples to be subjected to greater than 100° F. at a relative humidityof less than 60% prior to measuring the contact angle.

To conduct the contact angle test, 5-7 μL of Millipore purified water isdeposited on to the sample. High speed video imaging at 120 frames persecond is used to capture the contact and wetting of the drop on thesample. The contact angle measurement is taken on the second frame afterdetachment of the drop using First Ten Angstroms software available fromFirst Ten Angstroms, Inc. of Portsmouth, Va.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A roll of paper towel comprising a co-formedfibrous structure, wherein the co-formed fibrous structure comprisesfrom about 30% to 90% by dry weight of the co-formed fibrous structureof a plurality of wood pulp fibers and about 10% to about 70% by dryweight of the co-formed fibrous structure of a plurality of meltblownfilaments derived from a polymer composition comprising 100% by weightof the polymer composition of one or more biodegradable, thermoplasticpolymers selected from the group consisting of polylactic acid,polyhydroxyalkanoate, polycaprolactone, and mixtures thereof, whereinthe co-formed fibrous structure exhibits a contact angle of less than80° and wherein the plurality of wood pulp fibers are commingled withthe plurality of meltblown filaments.
 2. The roll of paper towelaccording to claim 1 wherein the co-formed fibrous structure exhibits acontact angle of less than 75°.
 3. The roll of paper towel according toclaim 1 wherein the co-formed fibrous structure further comprises awetting agent, wherein the wetting agent comprises a surfactant.
 4. Theroll of paper towel according to claim 1 wherein the co-formed fibrousstructure further comprises a wetting agent selected from the groupconsisting of: silicone surfactants, polyethylene glycols, glycols andmixtures thereof.
 5. The roll of paper towel according to claim 1wherein the co-formed fibrous structure further comprises a wettingagent, wherein the wetting agent is a melt additive wetting agent. 6.The roll of paper towel according to claim 1 wherein the one or morebiodegradable, thermoplastic polymers comprises polylactic acid.
 7. Theroll of paper towel according to claim 1 wherein the co-formed fibrousstructure comprises from about 40% to 80% by dry weight of the co-formedfibrous structure of the plurality of wood pulp fibers and from about20% to about 60% by dry weight of the co-formed fibrous structure of theplurality of meltblown filaments.
 8. The roll of paper towel accordingto claim 7 wherein the co-formed fibrous structure step of comprisesfrom about 50% to 70% by dry weight of the co-formed fibrous structureof a plurality of wood pulp fibers and from about 30% to about 50% bydry weight of the co-formed fibrous structure of the plurality ofmeltblown filaments.
 9. A package containing a roll of paper towel,wherein the roll of paper towel comprises a co-formed fibrous structure,wherein the co-formed fibrous structure comprises from about 30% to 90%by dry weight of the co-formed fibrous structure of a plurality of woodpulp fibers and about 10% to about 70% by dry weight of the co-formedfibrous structure of a plurality of meltblown filaments derived from apolymer composition comprising 100% by weight of the polymer compositionof one or more biodegradable, thermoplastic polymers, wherein theco-formed fibrous structure exhibits a contact angle of less than 80°and wherein the plurality of wood pulp fibers are commingled with theplurality of meltblown filaments.
 10. The package according to claim 9wherein the co-formed fibrous structure exhibits a contact angle of lessthan 75°.
 11. The package according to claim 9 wherein the co-formedfibrous structure further comprises a wetting agent, wherein the wettingagent comprises a surfactant.
 12. The package according to claim 9wherein the co-formed fibrous structure further comprises a wettingagent selected from the group consisting of: silicone surfactants,polyethylene glycols, glycols and mixtures thereof.
 13. The packageaccording to claim 9 wherein the co-formed fibrous structure furthercomprises a wetting agent, wherein the wetting agent is a melt additivewetting agent.
 14. The package according to claim 9 wherein the one ormore biodegradable, thermoplastic polymers comprises polylactic acid.15. The package according to claim 9 wherein the co-formed fibrousstructure comprises from about 40% to 80% by dry weight of the co-formedfibrous structure of the plurality of wood pulp fibers and from about20% to about 60% by dry weight of the co-formed fibrous structure of theplurality of meltblown filaments.
 16. The package according to claim 15wherein the co-formed fibrous structure step of comprises from about 50%to 70% by dry weight of the co-formed fibrous structure of a pluralityof wood pulp fibers and from about 30% to about 50% by dry weight of theco-formed fibrous structure of the plurality of meltblown filaments.